Related Manuals for Beckhoff KL6904
Summary of Contents for Beckhoff KL6904
- Page 1 Operating Instructions | EN KL6904 TwinSAFE logic terminal with 4 fail-safe outputs 2023-03-20 | Version: 3.0.0...
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Page 3: Table Of Contents
Safety concept ......................... 18 3.2.3 KL1904, KL2904 - Bus Terminals with 4 fail-safe inputs or outputs......... 19 3.2.4 KL6904 - TwinSAFE logic terminal with 4 fail-safe outputs.......... 19 3.2.5 The fail-safe principle (Fail Stop) .................. 19 4 Product description .......................... 20 KL6904 –... - Page 4 TwinSAFE group signals.................... 36 5.3.8 Append a function block.................... 37 5.3.9 KL6904 user and version administration................ 42 5.3.10 Loading the project into the KL6904 ................ 43 5.3.11 Communication between TwinCAT controllers .............. 45 6 Diagnosis .............................. 49 Diagnosis LEDs.......................... 49 6.1.1 Diag1 (green) ........................
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Page 5: Notes On The Documentation
Notes on the documentation Disclaimer Beckhoff products are subject to continuous further development. We reserve the right to revise the operating instructions at any time and without prior announcement. No claims for the modification of products that have already been supplied may be made on the basis of the data, diagrams and descriptions in these operating instructions. -
Page 6: Limitation Of Liability
Modifications and changes to the hardware and/or software configuration that go beyond the documented options are prohibited and nullify the liability of Beckhoff Automation GmbH & Co. KG. The following is excluded from the liability: •... -
Page 7: Documentation Issue Status
The original documentation is written in German. All other languages are derived from the German original. Product features Only the product properties specified in the current operating instructions are valid. Further information given on the product pages of the Beckhoff homepage, in emails or in other publications is not authoritative. KL6904 Version: 3.0.0... -
Page 8: Staff Qualification
• Independently identify, avoid and eliminate sources of hazard. • Apply relevant standards and directives. • Implement specifications from accident prevention regulations. • Evaluate, prepare and set up the workplaces. • Evaluate, optimize and execute work independently. Version: 3.0.0 KL6904... -
Page 9: Safety And Instruction
Notes are used for important information on the product. The possible consequences of failure to observe these include: • Malfunctions of the product • Damage to the product • Damage to the environment Information This sign indicates information, tips and notes for dealing with the product or the software. KL6904 Version: 3.0.0... -
Page 10: Beckhoff Support And Service
The employees support you in the programming and commissioning of sophisticated automation systems. Hotline: +49 5246/963-157 E-mail: support@beckhoff.com Web: www.beckhoff.com/support Training Training in Germany takes place in our training center at the Beckhoff headquarters in Verl, at subsidiaries or, by arrangement, at the customer's premises. Hotline: +49 5246/963-5000 E-mail: training@beckhoff.com Web: www.beckhoff.com/training... -
Page 11: For Your Safety
Products marked with a crossed-out waste bin must not be disposed of with domestic waste. The device is considered waste electrical and electronic equipment when it is disposed of. Observe the national regulations for the disposal of waste electrical and electronic equipment. KL6904 Version: 3.0.0... -
Page 12: Safety Image Signs
For your safety Safety image signs On Beckhoff products you will find attached or lasered safety pictograms, which vary depending on the product. They serve to serve to ensure safety for people and to prevent damage to the products. Safety pictograms must not be removed and must be legible for the user. -
Page 13: General Safety Instructions
De-energize and switch off components before working on them Check all safety-relevant equipment for functionality before working on the TwinSAFE component. Secure the working environment. Secure the machine or plant against being inadvertently started up. Observe the chapter Decommissioning [} 53]. KL6904 Version: 3.0.0... -
Page 14: System Description
System description The Beckhoff Bus Terminal system The Beckhoff Bus Terminal system is used for decentralized connection of sensors and actuators to a control system. The Beckhoff Bus Terminal system components are mainly used in industrial automation and building management applications. In its minimum configuration, a bus station consists of a Bus Coupler or a Bus Terminal Controller and Bus Terminals connected to it. -
Page 15: Bus Coupler
Connection technology Bus Coupler © Wiring cage Clamp spring-loaded system Connection cross-section 0.08 mm² ... 2.5 mm², stranded wire, solid wire Fieldbus connection depending on fieldbus Power contacts 3 spring contacts Current load 10 A Rated voltage 24 V KL6904 Version: 3.0.0... -
Page 16: Bus Terminals
Clamp spring-loaded system Connection cross-section 0.08 mm² ... 2.5 mm², stranded wire, solid wire Fieldbus connection depending on fieldbus Power contacts up to 3 blade/spring contacts Current load 10 A Rated voltage depends on Bus Terminal type Version: 3.0.0 KL6904... -
Page 17: K-Bus
The power feed terminals play no part in the control of the terminals and can be inserted at any locations within the terminal strip. KL6904 Version: 3.0.0... -
Page 18: Twinsafe
The new KLx9xx series Bus Terminals only include three basic functionalities: digital KL19xx inputs, digital KL29xx outputs and a KL6904 link unit. For a large number of applications, all sensors and actuators can be wired on these Bus Terminals. The required logical link of the inputs and the outputs is handled by the KL6904. -
Page 19: Kl1904, Kl2904 - Bus Terminals With 4 Fail-Safe Inputs Or Outputs
KL6904 - TwinSAFE logic terminal with 4 fail-safe outputs The KL6904 TwinSAFE logic terminal is a digital output terminal with four fail-safe outputs with 0.5 A, 24 VDC. The KL6904 meets the requirements of IEC 61508:2010 SIL 3 and DIN EN ISO 13849-1:2006 (Cat 4, PL e). -
Page 20: Product Description
0.5 A (24 V ). The Bus Terminal has 4 fail-safe outputs. The KL6904 meets the requirements of IEC 61508:2010 SIL 3, DIN EN ISO 13849-1:2006 (Cat 4, PL e), NRTL, UL508, UL1998 and UL991. The Bus Terminal has the standard design of a Beckhoff Bus Terminal. -
Page 21: Intended Use
Test pulses When selecting actuators please ensure that the KL6904 test pulses do not lead to actuator switching or diagnostic message from the KL6904. The test pulses of the KL6904 terminal outputs are not configurable and cannot be switched off. -
Page 22: Technical Data
Wire cross section min. 0.75 mm Input process image 192 byte max. Output process image 192 byte max. KL6904 supply voltage 24 V (–15% / +20%) Current consumption from K-bus max. 250 mA Power dissipation of the terminal typically 2 W... -
Page 23: Safety Parameters
Element classification Type B 1. Special proof tests are not required during the entire service life of the KL6904 Bus Terminal. 2. Classification according to IEC 61508-2:2010 (chapter 7.4.4.1.2 and 7.4.4.1.3) The KL6904 Bus Terminal can be used for safety-related applications within the meaning of IEC 61508:2010 up to SIL3 and EN ISO 13849-1 up to PL e (Cat4). -
Page 24: Operation
Please ensure that the digital TwinSAFE components are only transported and stored under the specified environmental conditions (see technical data). 5.2.3 Mechanical installation WARNING Risk of injury! Bring the bus system into a safe, de-energized state before starting installation, disassembly or wiring of the devices! Version: 3.0.0 KL6904... - Page 25 When installing the components, make sure that the locking mechanism doesn't come into conflict with the fixing bolts of the mounting rail. For fastening mounting rails with a height of 7.5 mm under the terminals and couplers, use flat fastening components such as countersunk head screws or blind rivets. KL6904 Version: 3.0.0...
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Page 26: Electrical Installation
(e.g. analog Bus Terminals or digital 4-channel Bus Terminals) do not or not fully loop through the power contacts. Power Feed Terminals (KL91xx, KL92xx) interrupt the power contacts and thus represent the start of a new supply rail. Version: 3.0.0 KL6904... - Page 27 The PE power contact must not be used for other potentials! 5.2.4.2 Overvoltage protection If protection against overvoltage is necessary in your plant, provide a surge filter for the voltage supply to the Bus Terminal blocks and the TwinSAFE terminals. KL6904 Version: 3.0.0...
- Page 28 3. The terminal closes automatically when the pressure is released, holding the wire safely and permanently. See the following table for the suitable wire size width. Wire size width (single core wires) 0.08 ... 2.5 mm Wire stripping length 8 ... 9 mm Version: 3.0.0 KL6904...
- Page 29 Test pulses When selecting actuators please ensure that the KL2904 test pulses do not lead to actuator switching or diagnostic message from the KL2904. The test pulses of the KL6904 terminal outputs are not configurable and cannot be switched off.
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Page 30: Configuration Of The Terminal In Twincat
KL6904. The current version is available for download from the Beckhoff website at www.beckhoff.de. In addition, the TwinSAFE Verifier must be installed. This is available on the Beckhoff Products & Solutions CD. The current installation can also be obtained from Beckhoff Support, if required. -
Page 31: Inserting A Kl6904
5.3.4 Inserting a KL6904 A KL6904 is inserted in the same way as any other Beckhoff Bus Terminal. In the list open Safety Terminals (KLx9xx) and select the KL6904. The KL6904 can be selected with 7 or 15 TwinSAFE connections. - Page 32 Operation Fig. 12: Configuration After the changeover to the new process image the KL6904 must be de-energized and switched on again in order to activate the change. Version: 3.0.0 KL6904...
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Page 33: Address Settings On Twinsafe Terminals With 1023 Possible Addresses
A TwinSAFE Group is a group of TwinSAFE terminals (inputs and outputs) that are logically linked via a KL6904. Any communication faults in the TwinSAFE connections of this group lead to the whole group being switched off. Other TwinSAFE groups are not affected. - Page 34 Operation A TwinSAFE Group is added by right-clicking on the associated KL6904 in the tree structure and selecting Append TwinSAFE Group in the dialog box (see diagram). Fig. 14: Creating a TwinSAFE group Version: 3.0.0 KL6904...
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Page 35: Twinsafe Group Signals
FALSE: All assigned function blocks have no errors Standard-Out COM ERR TwinSAFE-Out TRUE: At least one TwinSAFE connection of TwinSAFE group has an error FB-In FALSE: All TwinSAFE connections of the Standard-Out TwinSAFE group have no errors KL6904 Version: 3.0.0... - Page 36 STOP state and thus all associated outputs are in a safe state. ERR Ack FB-Out All pending errors in the assigned function blocks and in the TwinSAFE connections are acknowledged by Standard-In the FALSE->TRUE->FALSE signal sequence. Version: 3.0.0 KL6904...
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Page 37: Append A Function Block
5.3.8 Append a function block The KL6904 TwinSAFE logic terminal features the following blocks: Emergency Stop, Machine Monitoring, AND, OR, Decoupler, Operation Mode, etc. A function block is added by right-clicking on the associated TwinSAFE function block list in the tree structure and selecting Append Function Block in the dialog box with the left mouse button (see diagram). - Page 38 Operation Fig. 18: Possible function blocks Appended Emergency Stop block. Fig. 19: Added function block Version: 3.0.0 KL6904...
- Page 39 A Discrepancy Time can be set for monitoring the two inputs for simultaneous switching. • Make Contact: Contact type setting • Break Contact: Contact type setting The inputs are now activated. Fig. 21: Activated inputs The inputs can now be linked. KL6904 Version: 3.0.0...
- Page 40 Operation Fig. 22: Link input Select the variable type: Fig. 23: Select variable type Clicking on the New button opens the following dialog: Version: 3.0.0 KL6904...
- Page 41 The required channel is selected and highlighted in blue with the mouse. The selection is confirmed via the OK button. Fig. 25: Link channel The name of the variables should now be entered in the Link Alias field. KL6904 Version: 3.0.0...
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Page 42: Kl6904 User And Version Administration
Repeat the process for the other inputs. Inputs that are already in use are identified with an arrow. Fig. 27: Link further channel 5.3.9 KL6904 user and version administration The KL6904 has a user administration function. The administrator can create further users and issue associated passwords. Version: 3.0.0 KL6904... -
Page 43: Loading The Project Into The Kl6904
Operation Fig. 28: Version History Clicking on the Version History button will bring up the version history for the KL6904 (which cannot be deleted) that indicates who activated what version of a project on the KL6904, and when. 5.3.10 Loading the project into the KL6904 The project is loaded into the KL6904 via the fieldbus. - Page 44 Operation Fig. 29: Load project The project is then displayed in text mode, and the user has to confirm consistency between the information displayed and the currently projected application by re-entering the password. Fig. 30: Verify project Version: 3.0.0 KL6904...
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Page 45: Communication Between Twincat Controllers
TwinSAFE Slave Subscriber MASTER_MESSAGE The link with the via TwinSAFE logic terminal KL6904 is established with the following dialog: Fig. 31: Link TwinSAFE logic terminal The connection created must now be made known to the TwinSAFE logic terminal. This is done by marking the TwinSAFE connection list and pressing the right mouse button. - Page 46 One side must be a TwinSAFE master, the other one a TwinSAFE slave. The F address of the partner device must also be set. Please not the DIP switch on the left-hand side of the KL6904. Version: 3.0.0 KL6904...
- Page 47 Fig. 35: Set ID This ID must also be set on the partner device, i.e. the Subscriber. The network variables can now be used in the project. The inputs are shown under TwinSAFE Input, the outputs under TwinSAFE Output. KL6904 Version: 3.0.0...
- Page 48 Operation Fig. 36: Link input variable Fig. 37: Link output variable Version: 3.0.0 KL6904...
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Page 49: Diagnosis
4 flash pulses Output 4: Open load or current below minimum value of 20 mA or current above maximum value of 500 mA rapid flickering, alternating with 5 flash pulses Field voltage too low KL6904 Version: 3.0.0... -
Page 50: Diag3 (Red) And Diag4 (Red)
Diag3 (red) and Diag4 (red) The Diag 3 and Diag 4 LEDs indicate internal terminal errors. NOTE Returning the terminal These errors lead to shutdown of the terminal. The terminal must be checked by Beckhoff Automation GmbH & Co. KG. Diag3 Diag4... -
Page 51: Service Life
YY: Year of manufacture Year: 2011 SW: Software version Software version: 05 HW: Hardware version Hardware version: 00 In addition the TwinSAFE terminals bear a unique serial number. 00000000 17110500 Fig. 39: Unique serial number of a TwinSAFE terminal KL6904 Version: 3.0.0... -
Page 52: Maintenance And Cleaning
Maintenance and cleaning Cleaning by the manufacturer only Do not operate the TwinSAFE component if it is impermissibly dirty according to protection class IP20. Send impermissibly dirty TwinSAFE components to the manufacturer for cleaning. TwinSAFE components are basically maintenance-free. Version: 3.0.0 KL6904... -
Page 53: Decommissioning
In accordance with the WEEE-2012/19/EU directives, you can return used devices and accessories for professional disposal. The transport costs are borne by the sender. Send the used devices with the note "For disposal" to: Beckhoff Automation GmbH & Co. KG Gebäude „Service“ Stahlstraße 31... -
Page 54: Appendix
If there is customer specific data saved on the product, it cannot be ensured that this data might not be restored through for example forensic measures, even after the data is deleted through the provided tool chain. If this data is confidential, the scrapping of the product after usage is recommended to protect this data. Version: 3.0.0 KL6904... -
Page 55: Focus Of Certificates
The current certificates of all TwinSAFE components with the underlying standards and directives can be found at https://www.beckhoff.com/en-en/support/download-finder/certificates-approvals/. If the document refers only to the first four figures of a product (ELxxxx), the certificate is valid for all available variants of the component (ELxxxx-abcd). -
Page 56: Certificate
Appendix 10.3 Certificate Fig. 40: KL6904 EC Declaration of Conformity Version: 3.0.0 KL6904... - Page 58 More Information: Beckhoff Automation GmbH & Co. KG Hülshorstweg 20 33415 Verl Germany Phone: +49 5246 9630 info@beckhoff.com www.beckhoff.com...